Hmi Mark v Product Description

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GE Industrial Control Systems Power Generation Controls

Mark V HMI System Product Description

New Unit and Retrofit Applications

Revision 0 April 15, 1998

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Human Machine Interface for Mark V

© Copyright 1998 by General Electric Company, U.S.A. All rights reserved. Printed in the United States of America

CIMPLICITY, Genius, and Series 90 are registered trademarks of GE Fanuc Automation North America, Inc. Microsoft, Windows, Windows 95, Windows NT, and Excel are registered trademarks of Microsoft Corporation. ARCNET is a registered trademark of Datapoint Corporation. Ethernet is a trademark of Xerox Corporation. Modbus is a registered trademark of Groupe Schneider, Inc. IBM is a registered trademark of International Business Machines Corporation. PC is a registered trademark of International Business Machines Corporation. All other trademarks and registered trademarks are the property of their respective owners. All specifications are subject to change without written notice.

This product description is submitted in confidence for evaluation by the Purchaser, and its contents are proprietary to the GE Company. In taking receipt of this document, the Purchaser agrees not to reveal its contents except to those in its own organization who must evaluate it. Copies of this document may not be made without the prior written consent of GE.

Power Generation Controls HMI Mark V Product Description

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Table of Contents

1.0 Introduction .................................................................................... 5 2.0 System Configuration.................................................................... 6 3.0 Basic HMI System Description ................................................... 14 4.0 Communication Interfaces .......................................................... 22 5.0 Operator Functions ..................................................................... 24 6.0 Layered Control Functions ......................................................... 27 7.0 Maintenance and Tool Support .................................................. 30 8.0 Options and Accessories ............................................................ 34 9.0 Factory Testing and Quality Process......................................... 35 10.0 Technical Specifications ........................................................... 37 11.0 Reference Documents ............................................................... 38 12.0 Revision History ........................................................................ 39


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1.0 Introduction The Mark V HMI is a milestone for the turbine control marketplace. In one powerful, flexible and user-friendly operator interface, it brings together all of the displays and functions needed for real-time control and monitoring of turbomachinery processes, auxiliary equipment, driven devices and process diagnostic alarms associated with power plant control. As the operator interface for the power plant Integrated Control System (ICS), the HMI serves a variety of plant configurations. These systems can include gas turbines, steam turbines, hydraulic turbines, generator excitation systems, static starters, compressors, heat recovery steam generators (HRSGs), and balance of plant (BOP) auxiliaries. Today, more power generation units and functions are becoming integrated to achieve higher efficiencies and improved reliability and operator visualization. This requires that HMI systems deliver process information from a broader spectrum of controllers and compute platforms. Operators are demanding a comprehensive solution to meet their requirements, and no longer find multiple interface systems, each dedicated to their respective control systems, an acceptable alternative. The HMI system is playing an increasing role in delivering information to other members of the business management team. Users are demanding more integrated HMI systems to provide measurement of total plant operating efficiency, regulatory values, and data for business analysis. This means that future HMI systems must be able to access and deliver information to the business enterprise system as well as communicate to balance of plant control systems. Such enhanced functionality requires a more integrated solution and the use of open operating systems and hardware platforms. The Mark V HMI system provides the infrastructure needed to meet these demanding requirements. Designed with an open system concept, the system uses standard open hardware and operating system software. The HMI’s software system uses the Windows NT client-server architecture from Microsoft. Windows NT provides built-in multitasking, networking and security features. The ability to run the system on conventional PC based platforms minimizes cost, promotes open interfaces, permits system scalability, and ensures longevity of investment and future performance enhancement. The Mark V HMI system is firmly based on GE Industrial Systems (Salem, Virginia) and GE Fanuc Automation (Charlottesville, Virginia) products, which are in wide use on a variety of power generation and industrial applications. GE Fanuc’s widely used CIMPLICITY HMI serves as the foundation system. GE Industrial Systems configures and integrates the base CIMPLICITY product to create the Mark V HMI, making the system well-suited for the critical tasks of power island and power plant control.


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This combination of a state-of-the-art, open architecture HMI system from GE Fanuc, along with the power plant control experience and capability of GE Industrial Systems, provides an HMI product which is unique in the industry. The HMI System has the flexibility and capability to span a wide range of power island and balance of plant situations through a variety of interface mechanisms. Although the interfaces vary, the plant operators are still provided with a common visualization of plant operation and conditions.

2.0 System Configuration 2.1

Introduction The Mark V HMI system integrates plant operation at a single level. The system provides a common interface for the plant operators and engineers to view and control plant equipment.

2.2

System Structure The HMI system can provide plant visualization for control systems that span a wide range of equipment. Systems using the Mark V HMI may include one or more of the following types of equipment: • • • • • • • • • • • • • •

Mark V gas turbine control Mark V steam turbine control EX2000 generator exciter Generator Protection LCI Static Starters Historians Engineering Workstations for System Tools System and Documentation Printers Ethernet Networking Components Arcnet Networking Components Integrated third-party systems HRSG controllers Balance of plant controllers GE Integrated Control System

The HMI provides a common view for the operators and maintenance personnel into all of the above system equipment. Interconnections for plant control, display and data accumulation are made through Arcnet and Ethernet data highways, as


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indicated in the example configuration drawings of this section, and described below under item 4.0 on Communication. Systems span from simple retrofits involving replacement of a single existing processor to complete HMI or ICS systems on new plant installations. A number of example system configurations are offered later in this section to illustrate the breadth of HMI application scope. 2.3

HMI Retrofit Applications

The Mark V HMI can easily be added to existing installations due to the modular nature of the system. The equipment can be phased in, starting with a simple HMI retrofit of a single processor, and building over time into a complete ICS system. Downtime is minimized as a result of the system’s compatible products and software. In the typical retrofit application, the turbine control is existing, and the HMI is connected to an existing stage link. Existing Mark V operator interfaces can coexist and operate on the Stage Link with the new HMI based operator stations. This allows the new equipment to be added and commissioned while the existing interface to the turbine control is still in service, reducing risk of downtime during the installation. System configurations for retrofit applications vary, depending on the retained mix of existing and new equipment. In all configurations, the HMI’s flexibility allows users to enhance their existing control systems with modern operator interfaces, and obtain additional operating information to better manage their process. GE would be pleased to propose solutions for your process or existing equipment problems using the HMI equipment, and the ICS systems approach. 2.4

Example System Configurations The following items give examples of typical HMI system configurations for systems of various sizes and applications. These examples illustrate the wide application capability of the HMI system in both new and retrofit applications.


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2.4.1 Simple Mark V Replacement Configuration Mark V HMI

To DCS or other External Systems

Modbus

Stage Link

Mark V I/O AC

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GPP

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DC

+ -

Innovation

LCI Static Starter

EX2000 Exciter

Generator/ Transformer Protection

Gas Turbine Control New or Existing Equipment

This illustrates a simple HMI application, serving as an operator interface for a Mark V turbine control system. This usage could be on a new system, or as a retrofit application for an existing operator interface.


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Redundant Mark V Replacement Configuration

2.4.2

This illustrates a redundant HMI application, serving as an operator interface for a Mark V turbine control system. This usage could be on a new system, or as a retrofit application for an existing operator interface. Modbus to External DCS System HMI Server

HMI Server

Ethernet

Stage Link

Mark V I/O AC

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Control Room

GPP

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DC

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Innovation

LCI Static Starter

EX2000 Exciter


Gas Turbine Control New or Existing Equipment


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2.4.3

Typical Multi-Unit HMI System Configuration

This configuration shows two HMI servers in a host redundant configuration. The servers are located at the turbine equipment, and provide client, or viewer functionality at that location. The servers communicate over Ethernet to each other, to a viewer in the control room, and by Modbus to external DCS or other control systems. From the HMI stations, the operators can view either of the two turbine systems. The HMI is a true client-server system, and can be incrementally expanded as system needs change over time. Plant Data Highway (Ethernet)

HMI Server # 1

HMI Viewer

HMI Server # 2

Modbus to DCS System

In Control Room

Stage Link

Stage Link I/O AC

I/O g

g Mark V

GPP

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GPP

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EX2000 Exciter

LCI Static Starter Generator/ Transformer Protection


DC

+ -

Gas Turbine Control

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EX2000 Exciter Generator/ Transformer Protection

Steam Turbine Control

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2.4.4 Typical HMI System Including Analysis and Tool Systems

As indicated previously, the HMI system can be incrementally expanded. This configuration shows the system of Item 2.4.3 above, with the addition of a system Historian, and a separate engineering workstation. These devices could have been purchased with the original system, or added later as a retrofit. System printers for documentation and program development have been omitted from this drawing. Note that the Historian connects to the Stage Link directly. The Historian gathers its data directly from the control network. Historian data for display by the HMI and other systems is passed over the Ethernet data highway. Also note the Modbus and Ethernet interfaces to external third-party systems, such as DCS systems or PLCs. Such interfaces can be used for communication to a DCS, or to collect additional plant data for display on the HMI system. Ethernet interfaces use TCP/IP with a GE open messaging protocol. Modbus over Ethernet can also be used for these interfaces. Plant Data Highway (Ethernet)

HMI Server # 1

HMI Viewer

HMI Server # 2

Engineering Workstation

Historian

Dot Matrix

DAT Tape TR

DAT Tape TR

Control Room Dot Matrix

Modbus

Modbus Stage Link

Stage Link I/O AC

I/O g

GPP

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LCI Static Starter

+ -

g

GPP

g Mark V

Gas Turbine Control


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DC

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Modbus Ethernet DCS or Third-Party Systems Interfaces

EX2000 Exciter

EX2000 Exciter Generator/ Transformer Protection


DC


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2.4.5 Typical Full ICS System with HMI

The ICS (Integrated Control System) ties all of the plant’s controllers together, and provides visualization on the included HMI system. In the ICS, the auxiliary PLC based controllers for HRSG and balance of plant functions are integral to the system. Note that the Historian uses Modbus for data interface with the PLC controllers. Please see the ICS product description for more details about the GE Integrated Control System.


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LCI Static Starter

AC

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GPP


I/O Mark V DC

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GPP

I/O

TR


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HMI Viewer

TYPICAL MARK V ICS CONFIGURATION

EX2000 Exciter

HMI Server # 2

Gas Turbine Control

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Dot Matrix

Dot Matrix

Stage Link

HMI Server # 1

Plant Data Highway (Ethernet)

Mark V


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Stage Link

Historian

EX2000 Exciter

DC

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DAT Tape

TR

Modbus

TR

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90-70 PLC HRSG/Auxiliaries Hot Backup Rack

Fanuc 90/70 g

TR

90-70 PLC HRSG/Auxiliaries Primary Rack

LaserJet

Color InkJet

DAT Tape

Fanuc 90/70

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Plant Data Highway (Ethernet)

90-70 PLC HRSG/Auxiliaries Hot Backup Rack

90-70 PLC HRSG/Auxiliaries Primary Rack

Engineering Workstation

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3.0 Basic HMI System Description 3.1

Introduction The Mark V HMI system uses GE’s latest technology to produce a superior product for the power generation industry. GE Fanuc’s CIMPLICITY HMI system serves as the basic core system, which is then enhanced by the addition of power plant control hardware and software from GE Industrial Systems.

3.2

HMI Product Structure A Mark V HMI configuration consists of three distinct elements: 3.2.1

HMI Server The server is the hub of the system, and provides data support and system management. The HMI server also has the responsibility for device communication for both internal and external data interchanges.

3.2.2

System Signal Database The signal database establishes signal management and definition for the control system, provides a single repository for system alarm messages and definitions, and contains signal relationships and correlation between controllers and I/O used in the system.

3.2.3

HMI Viewer (Client) The viewer provides the visualization function for the system, and is the client of the distributed client-server system. The viewer contains the operator interface application software, which allows the operator or maintenance personnel to issue commands, edit coefficient values for system control, view screen graphics, data values, alarms, and trends, and provide system logs and reports.

Depending on the size of the target system, these three elements can be combined into a single PC, or can be distributed in multiple units. The modular nature of the HMI system allows units to be expanded incrementally, as needs change.


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3.3

CIMPLICITY HMI Product Features The HMI system includes a number of product features which are unmatched by other monitoring and control systems. These features bring value to the user of power plant control, and include the following: 3.3.1

Graphics - CimEdit and CimView The key functions of the HMI system are performed by its graphic system, which provides the operator with process visualization and control in a real-time environment. In the HMI system, this important interface is accomplished through CimEdit, a graphics editing package, and CimView, a high performance runtime viewing package. CimEdit is an object-oriented program that creates and maintains the graphic screen displays that represent the plant systems to the operators. Powerful editing and animation tools, with the familiar Windows environment, provide an intuitive interface that is easy to use. CimEdit includes a number of features, such as: • • • • • • • • • • • • • • • • • • •


Interactive, dynamic point configuration Point browser allows access to any point Standard shapes OLE embedded objects Wizard library, and ability to create new Wizards Movement and rotation animation Selectable filled object capabilities Interior and border animation of objects Event configuration Frame animation Hold last known value on points Windows file import capability Point search and replace Object scaling based on point values Scripting Undo / Redo on editor Visibility animation On-line and object help Dynamic screen testing

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CimView is the run-time portion of the HMI system, where the operator sees the process information displayed in graphic and textual formats. With CimView, the operators can view the system screens and screens from other applications via OLE automation, run scripts, get descriptions of object actions, and display system and object help. 3.3.2

Alarm Viewer Alarm Viewer provides alarm management functions for the HMI system. Alarm Viewer’s capabilities are based on GE’s years of experience in developing multi-user, multi-tasking supervisory monitoring and control systems. Alarm Viewer handles routing of alarms to the proper operator, and alarm sorting and filtering by priority, plant unit, time, or source device. It also includes the following features: • • • • •

3.3.3

Static and dynamic alarm modes Embeds into CimView screens as dynamically updated object Powerful alarm sorting and filtering capabilities Supports alarm acknowledgment Configurable display for alarm fields

Trending Capabilities HMI trending, based on OLE (object linking and embedding) technology, gives users powerful data analysis capabilities. Trending produces trend graphs from data collected by the HMI system, or data from other thirdparty software packages or interfaces. Data comparisons are supported between current and past variable data, allowing quick identification of process problems. Trending includes the following features: • • • • • •


Fully integrated with CimView Multiple trending charts per graphic screen Default parameters for easy setup and use Fully configurable by user Unlimited pens per chart Strong pen, chart and scale control capabilities

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3.3.4

Point Control Panel The HMI point control panel provides a listing of points in the system, with dynamically updating point values and alarm status. Operators have the ability to view and set local and remote points, enable and disable alarm generation, and modify alarm limits. Operators can also filter and sort points selectively, and save their filter setup parameters for repeated use.

3.3.5

Basic Control Engine The basic control engine allows users to define control actions to take in response to system events. It monitors event occurrence, and then executes configured actions in response. The basic control engine is supported by an event editor, and a program editor. The event editor allows definition of the actions that are to be taken in response to system events, which can be a changing point, alarm or time of day. A single event can invoke multiple actions, or one action can be invoked by many events. For more complex actions, the Program Editor allows creation of powerful programs that execute in response to events using a Visual Basic for Applications compliant programming language. The editor and rich set of language constructs provide a user-friendly environment, which enhances productivity in generating control action code. The following actions can occur based on an event: • • • • •

Set point values Acknowledge or clear alarms Create log file entries Invoke specific user-defined actions Invoke Visual Basic programs to execute user-defined logic

Basic control engine programs can be compiled as executable code for faster execution speed.


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3.3.6

Database Logger The database logger allows logging of data to a Microsoft Access file or a Microsoft SQL server. The logged data can include alarms, events and point values, and can be controlled and configured by the operator. Once logged, the data can be retrieved for reports, and is accessible from a variety of ODBC compliant applications. Logged database maintenance actions are configurable. Logged data is available to any user on the network with sufficient privilege. CIMPLICITY software is not required to view or access the data.

3.3.7

User Roles and Privileges CIMPLICITY allows configuration of system users to control access and privileges. Each user is assigned a user identity, and can be assigned a password. If a password is enabled, both ID and password are required for access. A user also has a resources property, which allows definition of the resources for which the user has access. In addition to identity, each user is assigned a role, and each role has certain privilege levels. These privileges define the functions that the user role can access. If a user lacks privilege to access a secure function, an error message is displayed, and access is denied.

3.3.8

DDE Application Interface The DDE Interface allows other Windows applications that use Microsoft standard and Advanced DDE to obtain easy access to HMI point data. Users can integrate software that supports DDE to monitor, analyze report or modify the HMI point data. In addition, the HMI provides advanced DDE client communications for data collection from third-party devices.


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3.4

Optional HMI Product Features 3.4.1

Server Redundancy Option Server redundancy, an option for CIMPLICITY HMI Windows NT servers, provides automatic switchover from a primary system to a secondary system in case of a computer failure. Coupled with Ethernet redundancy, this offers users a complete redundant solution for those applications in which maintenance of HMI operations is critical. With server redundancy, point values, alarms and data logging are kept synchronized between the two systems. In a failover, the incoming secondary system is completely current, and the switchover is virtually transparent to the operators.

3.4.2

Historical Data Analyzer The historical data analyzer provides functions for data analysis without the need for complex programming or query commands. It includes enhanced data logging functions, historical data viewing, and data modification and recalculation. The analyzer’s advanced summarization functions allow selection of the type of analysis to be automatically performed on the collected data. Calculations include: • • • • • •

Average Accumulator Rate of change Minimum value Maximum value Last valid value

Periods for the analysis can be standard periods such as minutes, hours, days, weeks, months or years.


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3.4.3

Statistical Process Control (SPC) The SPC function provides tools to create and maintain a statistical process control analysis of the process. The HMI with SPC supports the four major phases of such a program, which include: • • • •

Measurement - The ability to collect large amounts of accurate data Analysis - The ability to transform data into meaningful information Improvement - The ability to use information to change the process and increase quality Control - The ability to monitor the process continually and react to new information as it appears in order to maintain quality levels

With the HMI, data collection can be accomplished automatically from process sensors, or manually through input devices. Once the data is collected, SPC provides industry standard statistical tools to analyze the data and transform it to useful information. With the measurement and analysis phases automated, users are free to concentrate on the improvement phase of their quality program. The SPC is also critical during the control phase, monitoring the changes in the process, and verifying the results. 3.4.4

Pager The CIMPLICITY Pager, based on Netcon’s FirstPAGE technology, allows complete integration of HMI alarms with standard external paging systems based on IXO and TAP protocols. These include Sky-Tel and local paging systems. Pager is ideal for operators who need to move freely around the facility. Pager features include: • • • • • • • • •


On-line configuration of users and paging numbers Ability to enable or disable users from receiving pages Escalating pages linked to alarm states and other conditions Filtering based on alarm resources, classes or Ids Dynamic on-line configuration Basic control engine interface, for custom paging logic Customizable pager messages Configuration templates for fast setup Support of distribution lists

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The Pager function keeps users connected to the process, and allows them to get ahead of a problem before it becomes a crisis. 3.4.5

WebGateway The HMI WebGateway allows users to access HMI data from anywhere in the world over the Internet. This option is configured to work with a Microsoft Internet Server. WebGateway lets users create web documents (standard HTML format) containing textual HMI data values. It is also possible to include graphical representations of the process as bitmaps to further enhance the remote screens. Dialing in from a remote location, users can then view the process, and perform set points, if allowed. The WebGateway provides support for multiple remote users. The HMI security features filter the access and privileges given to remote users, in the same manner as for the local multiple-user system.

3.4.6

Third-Party Interfaces The HMI system can exchange data with DCS systems, programmable logic controllers, I/O devices, and other computers supplied by major control manufacturers. A broad range of communication products and ability to integrate third-party DDE interfaces allow users to interface their existing or new third-party equipment to the CIMPLICITY HMI system. Please inquire regarding specific interfaces, as the available list continues to expand.


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4.0 Communication Interfaces 4.1

Compatibility The MARK V HMI system can serve either new or retrofit applications, and retains the capability to perform the functions of the older GE Mark V operator interface versions. MARK V HMI is compatible with all Mark V controller applications, including both heavy duty and aero-derivative gas turbines, steam turbines, boiler feedpump turbines, single-shaft STAG combined-cycle units, and turbine generator monitoring. A single unit will serve up to eight (8) turbine controllers or equivalent units. Adding a MARK V HMI to an existing site will not conflict with any existing or units that are retained. The new system will support the existing Mark V control signal database (CSDB).

4.2

Stage Link The Mark V HMI uses Stage Link as its mechanism for communication with the GE Mark V turbine controllers and ancillary equipment. Stage Link is based on an Arcnet communications network. This interface is at the HMI server level. The HMI can be located locally to the Mark V control, or remotely within the distance limitations of the Stage Link system. A single HMI can communicate with up to eight (8) Mark V type controls on a common Stage Link.

4.3

Ethernet The Plant Data Highway (PDH) serves to integrate the unit turbine control systems with the overall plant and external communication requirements. The HMI viewer stations connect to the PDH, and receive their data from the servers over this network. Since this network is intended to provide external interface, it uses open and widely used communication interfaces, such as TCP/IP. Use of TCP/IP on Ethernet minimizes impact on the systems being interfaced. The HMI additionally allows Modbus interfaces with other systems. These open interfaces allow Mark V HMI to collect and display data from a variety of plant-wide sources. The MARK V HMI will supervise extended equipment, such as HRSG and balance of plant auxiliaries, through structured GE Fanuc Series 90 PLC interfaces. The HMI will use Genius and Field Control I/O accessed through the PLCs as operator interfaces, and will provide a consistent tool set to configure this equipment.


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4.4

Historian

[Optional]

Some Mark V systems include an optional historian function, which can be implemented in an HMI computer, or in a separate computer. The historian collects defined data from the equipment under control, and archives this data for later display and analysis. Like the HMI system, the historian functions will be implemented on a Windows NT based system. When such a system is present, the HMI can display data for monitoring, plotting historical information, and data management, including the tools necessary to configure the data interface functions. 4.5

Time Management

[Optional]

Time synchronization capability is provided in the Mark V HMI, in both low and high-resolution forms. The low-resolution form is based on local Mark V HMI PC clocks, and will hold slave PCs within a steady-state error of ± 250 msec of the master PC’s clock. The high resolution form uses an optional processing board in the PC, and can track externally generated IRIG-B modulated time code signals, to produce synchronization with a steady-state error of ± 1 msec. Redundant time masters can be employed on a single Stage Link, in any combination of low or high-resolution masters. When redundant masters are available, all Mark V control panels, any existing Mark V s, and Mark V HMI units will automatically select the same, highest quality time master. Failure of the selected master will result in selection of another common master by the entities on the link. 4.5

Other Interfaces

[Optional]

Some turbine systems also include other optional GE or third party equipment that is structured into the GE control and operator interface systems. The Mark V HMI will provide interfaces and display information from the following: • • • •


GE On Site Monitor (OSM) for display of collected data GE Reuter-Stokes Gas Turbine Predictive Emissions Monitoring System (GTPEMS) Bently Nevada DM2000 vibration monitoring equipment, for display to the operators GE Harris Utility Energy Management Systems

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5.0 Operator Functions 5.1

Display Management Display management for the Mark V HMI provides overall display functions to meet the needs of the turbine plant. These include the following:

5.2

•

Displayed data will be a combination of data received over Ethernet from GE or third-party servers, or over the Stage Link, from Mark V controllers

•

Alarm display connection to external alarm management function

Special Displays Turbine systems may have either basic or optional equipment that requires special displays for operation, including the following: •

Hold List Display, for those turbine systems that have Automatic Turbine Startup (ATS) functions. The hold list is a set of conditions, which must be met at certain times, speeds and operating modes in the turbine startup. The HMI provides for the creation, modification, display, printing, down and up loading, compiling and reverse translation of a hold list of up to 64 points.

•

Reactive Capability Display, showing an X-Y display of real and reactive power. The plot shows three lines of generator capability as a function of generator coolant temperature.

•

Timer, Counter, Accumulator Display, showing the settings and totals in the Mark V controllers.

•

Screen Copy, which makes a copy of a screen image, and stores it in the Windows clipboard. Screen print through standard Windows printers. This can also be redirected to a file. Files can then be re-displayed, printed, or transmitted electronically for remote viewing.


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5.3

Logging

[Optional]

Some optional Mark V HMI logging functions require third-party software such as Microsoft Access database or Microsoft SQL server software. These packages include the following functions:

5.4

•

Alarm and Event Log, to document normal sequence logic that is defined as an event in the control system. Events are normally selected to define points in sequences, such as minimum speed on a gas turbine to initiate firing. The events can be logged, and the operator can select any combination of events, alarms, or contact inputs to include in the log. Logs can be written to disk, printed, or made available for remote transmission.

•

Periodic Data Log, to log selected data points on a selected periodic rate, which can be as short as one second, or as long as one week. Data output will normally go to a file. Several instances of logs can run concurrently, and tools are provided to configure and manage the data for these logs.

•

Sequence of Events (SOE) Log, for the Mark V controller contact inputs, which are time tagged to one msec. This data can be merged into the Alarm and Event log, above. The HMI will be able to display or print the SOE listing, which will include the machine, date, time, point name and the new state.

Trip History Each Mark V control unit collects a set of data for a trip history to enable analysis of trip events. The data set covers a time frame that spans the actual trip. On a trip event, the Mark V HMI will collect the trip history data from the Mark V controller to avoid it being overwritten. The trip history data can be plotted, printed as tabular data, or transmitted electronically for remote analysis. The data set for the previous 10 trip events for each Mark V control will be retained.


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5.5

Process Alarm Management The features of process alarm management help the operator make a proper response to alarms, and include the following: •

Alarm queue display for each of the Mark V unit controls. The unit controller maintains the official unit alarm list, and the HMI will obtain and display alarm states and information from one or all control units.

•

A main alarm display will include all plant alarms.

•

The HMI will print or store the real-time alarm log as configured by the operator. Storage will be included for up to five days of alarms.

•

Alarm lockout for toggling Mark V alarm conditions will be provided by the HMI. Locked alarms will continue to be represented on the unit or plant alarm displays, so that an active alarm is displayed as either active or locked.

•

The HMI will provide an alarm notepad function, which will allow the operator to add an explanatory note to each active alarm drop number for each panel. Viewing or printing of these notes can be initiated from the alarm display.

•

Alarms can be linked to pre-selected related display screens. Clicking on the alarms will bring up the selected display to provide additional data.

•

Alarm help will provide a more detailed description of the alarm, and a description of the intended function in alarm.

•

Equipment diagnostic alarms are displayed such that the operators recognize them as separate from regular alarms or events.


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6.0 Layered Control Functions The Mark V HMI system includes a number of higher-level structured control functions that are available as options. These functions generally assist operators in control of the overall power plant system. 6.1

Multi-Unit Load Control In a multi-turbine plant, the multi-unit load control function (MLC) will allow the operator to enter the desired total plant load, and the control will automatically regulate the plant to the desired power output. The control will include compensation for system frequency variation. Unit balance control will be adjustable. The operator can also select whether individual turbines participate in the plant load regulation. For instance, the operator may choose to leave a particularly efficient machine out of the regulating group, and set it to operate at base load. The HMI will display the selection status and current power output levels of plant turbines, and facilitate changing the plant setpoints, and the turbine regulating setups.

6.2

Isochronous Load Sharing Isochronous Load Sharing (ILS) allows a multi-unit plant to reset system frequency to rated value while sharing load between turbines, both transiently and steady state. The system will handle loads up to the rating of the plant, shared proportionally to the rating of each machine. The operator can select or de-select turbine generators to participate in the ILS, with no load bump occurring on transition. Deselected units will run on droop control, with load established by the operator. For selected units, participation weighting will normally be proportional to the unit rating, but the operator will have the ability to adjust unit weighting with both gain and offset, as well as to bias collective system frequency setpoint. Under ILS, a step in load will cause system frequency to move, and all the selected machines will adjust load in proportion to their size and isochronous gain, both transiently and for the new steady state condition. System frequency will return to the setpoint value, with load shared proportionally.


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In order to keep availability high, redundant power transducers are needed for this option. All units must dynamically share information on ratings, output, selection for participation, and operator settings to implement this function, and redundant transducers will help avoid unnecessary upset. 6.3

Performance Monitor Performance Monitor is a simple cycle gas turbine and generator program that calculates and displays relative overall efficiency and component efficiencies, including the inlet, compressor, turbine and exhaust. The option includes special low drift sensors for the turbine, which are required for best results. The calculation approach uses a base line data set and compares in the turbine over time. The HMI will include screens to allow establishing the base line, and normal operating screens showing the efficiency data.

6.4

Historical Functions The Mark V HMI supports a Windows NT based historian computer, which collects and stores data from the control units for later analysis. The HMI can access the historical data for certain structured functions, as follows:

6.5

•

A historical data plot program will plot up to six (6) historical points versus time. The operator can specify the start time, elapsed time, list of points and scaling. The HMI plots can be displayed, printed or saved to a file for further processing. Multiple plots can be displayed simultaneously.

•

The historical alarm and event report will display alarms, events and sequence of events (SOE) for a specified time range, in a format similar to the normal alarm display. The report can be displayed, printed or saved to file.

Remote Control Interface For Ethernet TCP/IP communication to third-party equipment (such as DCS systems), the Mark V HMI will provide GSM and Modbus protocol. GSM and Modbus over TCP/IP application layer protocols support four classes of application level messages, which include administration, event driven, periodic data and common request messages. The protocol format is documented in an available technical instruction (GEI-100165). GSM is often provided on a separate computer server when a large volume of remote control information is required.


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Alternatively, communication to remote DCS equipment is available through a Modbus interface, where the Mark V HMI acts as a slave to the DCS master. Such a system allows an operator at a remote location to initiate any operator command, and monitor data from the Mark V controller signal database. Speed of this interface may limit the amount of data that can be accommodated


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7.0 Maintenance and Tool Support The Mark V HMI includes features to aid and enhance maintenance and tool actions with both the HMI system as well as the plant Mark V turbine controllers, as described below. 7.1

Remote Access The Mark V HMI system supports remote access by customers, field engineers or GE Industrial Systems personnel. The customer maintains full control over the access to the system. Such access aids in field installation, troubleshooting of Mark V controllers and the HMI, and in resolving general maintenance problems of the controller and HMI systems. In remote access, a computer in the remote location appears as a View node on the site system. Capabilities include operation displays, configuration of the HMI and Mark V controllers, real-time and historical data retrieval, maintenance operations such as View programs, diagnostic alarms, and constant changes.

7.2

Diagnostic Alarms Diagnostic alarms are similar to process alarms, but pertain to the control system. The features of the diagnostic alarms system will help operators and maintenance personnel respond to control system problems, and include: •

Diagnostic alarms are a separate type of alarm under the common alarm system, with similar power in providing the operator with sorting and grouping capabilities.

•

If selected, the HMI will print diagnostic alarms on the alarm printer, in addition to the process alarms.

•

Alarm help is provided for the diagnostic alarms, in a manner similar to that provided for the process alarms. Clicking on an alarm brings up information about the cause, effect and actions to take for the alarm response.


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7.3

VIEW Programs A set of special data collection programs, known as View Programs, will provide for collection of data necessary to troubleshoot the Mark V unit control systems. These programs will create diagnostic data files that will be stored for later analysis. Files can be displayed, trended, printed, faxed or transferred across a remote link. The View program data will include the following:

7.4

•

VIEW1 - A named data collection, manually initiated and stopped, from entered point names, collected at 1 Hz.

•

VIEW2 - Data collector to accumulate data from , , , , or in the Mark V controller. Collection stops when specified number of samples is reached, or when defined memory is full. Scan rate is specified in controller clock ticks.

•

VIEW2T - High speed triggered data collection program. Collection is triggered by a specific logic variable, and collects pre and post trigger data in the amount specified.

•

VIEWPV - Special program that allows collection of the unit pre-vote data at high speed.

•

VIEWQ - Program that allows collection of data from each of the processors.

•

VIEWPIA - Program that retrieves data from the Historian, and displays it point by point with the data time tag.

Control Hierarchy The system control hierarchy establishes allowable command locations for each Mark V controller unit. System elements that can originate a command are called control ports, which consist only of Ethernet and Modbus links. Hierarchy is implemented by definition of control ports that are allowed to send commands to a unit, based on the unit’s current mode. Based on these definitions, each controller unit will store its own current control locations within the unit, and will respond only to commands from those control locations.


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7.5

Valve Automatic Calibrate The HMI will support an autocalibrate function, which will allow a user to calibrate the feedback signals in the position control of the Mark V controller servovalve outputs. Calibration will be performed by the Mark V regulator card, from inputs downloaded from the HMI processor. Two verify functions will confirm calibration by data collection while ramping the valve from stop to stop.

7.6

Pre-Vote Display The Mark V HMI will provide a pre-vote display for TMR controllers. The display will allow viewing of logic and analog I/O values before voting by the three independent controllers to select a value. The voted value will also be displayed.

7.7

Logic Forcing Logic forcing will be supported by the HMI system, using a logic forcing display program. Identity and status of forced points will be maintained by the system. Forcing and unforcing of points will require an arm - execute command, and will be available only to authorized users.

7.8

Control Constants Control constants are tune-up parameters and variables that change with each application, and may change from time to time during the life of an installation. The HMI will provide a control constant display showing all applicable values for a Mark V control unit. The HMI will also have the ability to adjust the values of control constants, with appropriate ramp rates, and min and max values. The HMI will include a tool to create and maintain a control constant file on a unit basis, which can be downloaded to the unit controller.


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7.9

Configuration Tools The HMI system will provide tools to configure a Mark V control panel. These tools will include up and down loaders, compilers, and reverse translators. The configuration tools will include: •

I/O configurator for Mark V embedded I/O software

•

Control Sequence Program (CSP) Editor, to edit existing control program segments, or to create new program segments

•

Panel configuration, including maintenance of the Data Dictionary File System (DDFS) and the Control Signal Data Base (CSDB)

•

Capability to configure the Mark V backup operator interface

•

Ability to configure the Mark V unit trip logs


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8.0 Options and Accessories 8.1

Hardware Options The following options are available for the HMI hardware: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

8.2

Server redundancy Industrial grade PC equipment Rack mount PC equipment UPS support Additional viewer stations Increased monitor size Laser and color printer additions Optional interfaces Arcnet and Ethernet cabling options Time synchronization hardware for servers Historian

Software Options 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.


GE Harris interface software GE OSM interface software Predictive Emissions Monitoring System interface software Bently Nevada interface software Multi-unit load control Isochronous load sharing Performance monitor Historian data interfaces Historical data analyzer Statistical process control Pager WebGateway Remote control interface Third-party compatibility interfaces Custom display frames Custom reporting, logging, analysis programs Valve auto calibrate software

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9.0 Factory Testing and Quality Process 9.1

Factory Testing The HMI hardware consists primarily of commercially available conventional or industrial PC equipment. Testing of the individual components is performed by the manufacturer(s) prior to delivery to the GE integration site. Further testing is performed during and following integration to confirm correctness of the hardware component set, its configuration, and the software load. The Mark V HMI PC computer hardware is integrated using a process called FCP (Factory Clone Process), which is designed to ensure that the computer equipment is shipped as ordered, identical to similar units, and in perfect working condition. 9.1.1

Database Initialization When HMI units are ordered, a project coordinator creates the order/unit number in the FCP database. This action results in the production of a hardware component pick list, product-specific buildsheets, and initiates component accumulation. This stage also prints all necessary manuals and documentation needed by the system.

9.1.2

Unit Integration All material and components for the ordered unit(s) are collected and palletized as a complete kit for the integration process. The integration technician receives the kit, and performs the hardware integration in accordance with the product specific buildsheets. These buildsheets describe the specific steps that the technician must perform, and even include information such as jumper settings for interrupts, ports, terminations or device addresses. Following integration, the unit receives a final internal inspection by a different technician, to make a second verification of the accuracy of the integration.

9.1.3

Unit FCP Testing The unit is then started on test software, and the FCP automated testing process begins. From the original order/unit number, the system verifies that all of the parts on the original order have been integrated into the unit. The unit then undergoes diagnostic testing, in which all of the integrated


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components must pass point-to-point functionality tests. Should the FCP detect a failure during this operation, the diagnostic is terminated. The technician must then correct the problem, and start the diagnostic from the beginning. This ensures that the technician did not inadvertently disturb a connection that had already been checked. 9.1.4

Software Load Following completion of the hardware diagnostics, the software is loaded as a disk image. In this operation, a disk image containing the operating system, all drivers, and the application software is copied to the disk of the target machine. This “cloning” process ensures that all software loads are the same, and are complete, eliminating potential for the technician to leave out a component of the software.

9.1.5

Final Functional Test Once software is loaded, the system peripherals are connected, and the completed unit is started and tested for overall functionality, completing the testing process for the HMI computer unit.

9.2

Quality Process GE is committed to setting the industry standard of excellence for customer satisfaction. Inherent in this objective is a continuing determination to perform every function and to hold every process to the highest quality standards, from the way technologies are developed to the way products are manufactured and services are provided to our customers. In support of this end, GE has initiated a separately staffed continuous improvement process, which is a disciplined statistical approach, to continually measure, analyze, improve and control all production and service processes, including factory hardware and software testing.


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10.0 Technical Specifications 10.1

HMI Servers, HMI Viewers • Intel based PC • 166 MHz Pentium processor or better • 64 MB RAM • 512 KB cache memory • Hard drive 2.5 GB or greater (multiple on historian) • Floppy drive 1.44 MB • Video card with 2 MB DRAM • 15 inch monitor or better • CD 8 x or better, with multi-read capability • 2 serial and 1 parallel port • Windows NT operating system • Keyboard • Trackball or mouse • Ethernet interface • DAT tape drives on historian and engineering workstations • Modems on HMI servers

10.2

Dot Matrix Printer • Wide carriage 24 pin dot-matrix • Centronics parallel interface • Tractor feed mechanism

10.3

Laser Printer • Hewlett Packard laser printer • 12 pages per minute or better • 600 x 600 dpi • HP JetDirect Ethernet card • Capable of handling tabloid (11 x 17″) or A4 media

10.4

Color Printer • Hewlett Packard color inkjet printer • Eight pages per minute black at 600 x 600 dpi • One to three pages per minute color at 300 x 300 dpi • HP JetDirect Ethernet card • Capable of handling tabloid (11 x 17″) or A4 media


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11.0 Reference Documents 11.1

Document List Additional information on the Mark V System equipment is available in the following documents: Id No.

Title

File

Format

PD-ics5 PD-m5hgn PD-m5msn PD-gpp

ICS Product Description HD GT Product Description Med. ST Product Description Generator Protection Panel Product Description LCI Static Starter Product Description HRSG – PLC Product Desc. Balance of Plant – PLC Product Description HMI Product Description Historian Product Description

*.pdf *.pdf *.pdf *.pdf

Adobe Acrobat Adobe Acrobat Adobe Acrobat Adobe Acrobat

*.pdf

Adobe Acrobat

*.pdf *.pdf

Adobe Acrobat Adobe Acrobat

*.pdf *.pdf

Adobe Acrobat Adobe Acrobat

PD-lciss PD-hrsg-plc PD-bop-plc PD-hmi5 PD-hist5


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12.0 Revision History

Revision Number 0


Revision Date 4/15/98

Revision Original creation

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Hmi Mark v Product Description

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